Safety Warning
DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.
1991 Suzuki Samurai JSFACTORY OEM SERVICE PROCEDURE
Fuel Pump Circuit Test
- When ignition switch is first turned on with engine off, fuel pump should operate for 2 seconds. If fuel pump does not operate, connect Pink/Blue and Blue/Black wires of fuel pump relay harness using jumper wire. Fuel pump relay is located under far right side of dash, above ECM. If fuel pump operates, go to next step. If fuel pump DOES NOT operate, go to step 4).
- If fuel pump operates, check for power at Black/White wire terminal of fuel pump relay. If power is not present, check fuse No. 7 and Black/White wiring circuit to fuel pump relay and repair as required. If power is present at Black/White wire terminal of fuel pump relay, check Pink wire ground circuit from fuel pump relay to ECM.
- To test fuel pump relay and/or ground circuit, ground Pink wire terminal of fuel pump relay and listen for fuel pump operation. If fuel pump operates, relay is okay. Check Pink wire ground circuit to ECM and repair as required. If ground circuit is okay, replace ECM. If fuel pump does not operate and there is power at Blue/Black and Black/White wire terminals, replace relay.
- If fuel pump did not operate in step 1), check for power at Blue/Black wire terminal of relay. If relay terminal has power, check for power at Pink/Blue wire terminal of fuel pump connector. If wire terminal does not have power, repair Pink/Blue wiring circuit to fuel pump. If fuel pump does have power, check ground wire circuit. If ground wire circuit is okay, replace fuel pump.
Factory Service Tools
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When to See a Mechanic
Stop DIY work and contact a certified mechanic immediately if any of the following apply:
- • You smell fuel, burning insulation, or see smoke.
- • Brakes feel soft, pull hard to one side, or make grinding noises.
- • The engine overheats, stalls repeatedly, or misfires under load.
- • You are missing required tools, torque specs, or safe lifting equipment.
- • You are not confident in the next step or safety outcome.
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